Smart Cord Reel

ABSTRACT

A smart cord reel cable including at least one sensor for measuring cord or cord reel usage, a memory for receiving sensor input to create usage records, and a processor for analyzing the usage records to provide information for maintenance status indication and/or usage analytics.

RELATED APPLICATIONS

This application is a continuation in part of U.S. patent applicationSer. No. 15/175,822, filed Jun. 7, 2016. In addition, this applicationclaims priority to Provisional Application No. 62/346,904, filed Jun. 7,2016.

FIELD OF INVENTION

The present disclosure relates to a system for the recording andanalysis of use of electrical or mechanical cords involving connectionto electronics devices, such as an phone, tablet laptop or passengercontrol unit. More specifically, the present disclosure includes a cordreel having a memory which can be connected to an electronic device suchas a phone, tablet laptop or passenger control unit to receiveinformation related to the use of the cord reel and to create recordstherefrom so as to provide information to authorized personnel for theusage statistics, maintenance, servicing, and/or design improvement ofthe cord and/or cord reel.

BACKGROUND OF THE INVENTION

Retractable reels have been used in various applications to retractablystore various types of cables or cords. For example, one successful cordreel assembly has been developed that comprises a spool on which theextendable portion of cord is held, an expansion chamber in which afixed length of cable is spirally wound. The two cable portions areconnected, typically in or adjacent the hub of the spool. As the spoolrotates the spirally wound, fixed cable expands and contracts within theexpansion chamber. Examples of reels of this type are disclosed in U.S.Pat. No. 5,094,396 to Burke and U.S. Pat. No. 8,075,335 to Burke et al.,the disclosures of which are hereby incorporated by reference.

Retractable cord reels have been used in various applications toretractably store various types of cables. Using a reel providesconvenient storage for the cord. The reel also protects the cord fromdamage, since it need not be left on the ground. Damage to the cord isreduced. In the case of an electrical cord reel, the hazard presented toa user by a damaged electrical cord is also avoided. However, cord usage(e.g., the wear of the cord) may vary, even across (for instance)various cord reels installed in different seats on the same aircraft.Furthermore, given the variance in wear across such similarly situatedcords and/or cord reels, the ability to predict and anticipate the needfor replacement or repair of a given unit is likely to be a function ofthe number of uses (i.e., rotations) employed by the given cord reel. Afurther necessary point of information in judging the durability of suchcords and/or cord reels is obtaining knowledge about the installationdates and circumstances relate to such devices. Also, certain types ofapplications may involve varying usage durations and extensions of thecord, and the knowledge of such usage could benefit the ongoingimprovement in design of the cord and/or cord reel. In addition, it maybe desirable to predict the next service date for the cord reelassembly, to know the initial installation date of the cord reelassembly, and other information relative to its installation and/or use.

In order to provide a more durable and more reliable system forconnecting to and supporting electronics attached to cords and/or cordreels, it is necessary to provide a mechanism to enable the recording ofusage of such devices and/or the prediction of the failure of suchdevices. The needs for such a system also exist in other areas outsideof an aerospace application, such as in a retail environment, where dataabout the duration of frequency and use may be used in addition orseparate from maintenance requirements, such as a retailer's need totrack the frequency and duration that customers pick up and use floorsamples of a given device tethered via cord for security purposes.

To date, however, there are no available products that permit a cord orcord reel assembly to provide a mechanism to record usage events, nor doany available devices provide a method for anticipating the need forreplacement of such devices prior to failure.

What is needed is system including the ability to record and analyzeevents related to the usage of cord or a cord reel assembly.

DEFINITION OF TERMS

The following terms are used in the claims of the patent as filed andare intended to have their broadest plain and ordinary meaningconsistent with the requirements of the law.

The “processor” refers to a computer that can be accessed by authorizedpersonnel, such as a service technician, flight crew, flight attendant,owner, agent or the like through a number of different structures, suchas through interrogation of a given cord reel by a wireless devicehaving the processor external to the cord reel assembly, and/or a cloudor remote server based processor for gathering sensor information eachof a plurality of cord reel assemblies, and/or a processor located onthe cord reel assembly which can be interrogated by a tablet or the likeoperated by the technician, or which can be accessed through a displaypanel electrically connected to the cord reel assembly.

The “first sensor mechanism” refers to circuitry for detecting andmeasuring rotational movement, such as one or more magnets incombination with a Hall effect sensor, or an optical sensor (e.g., foruse with a color coated cord) or the like.

“Usage analytic records” means data structures that are generated andrecorded related to the installation and operation of the cord reelassembly, including for instance, first date in use, serial number,maintenance records, install type, installation location and parameters,frequency of use, and extent of use.

A “maintenance access mechanism” is a mechanical and/or wirelessinterface for enabling a maintenance worker to access an additionalportion of the cord including the connector for replacement and/orservice. Examples of such mechanisms include a solenoid actuated byremote wireless interface, a hidden mechanical button such as one on theholder, or a discreet tool-actuated aperture on the holder so as tounlock access to the additional portion of the cord.

A “maintenance worker” means any authorized personnel, such as a servicetechnician, flight crew, flight attendant, owner, agent or the like.

A “connector” means an electrical and/or mechanical connection betweentwo segments of a cord that include a locking mechanism for normal cordusage that can be released or decoupled during service events. Anexample of such connectors would be barrel connectors or the like.

Where alternative meanings are possible, the broadest meaning isintended. All words used in the claims set forth below are intended tobe used in the normal, customary usage of grammar and the Englishlanguage.

Objects and Summary of the Disclosure

The apparatus and method of the present disclosure generally includes acable (either data, electrical or mechanical) that is preferablyconnected to cord reel housing or spool, or alternatively anothercontainer. Such a smart cord reel system will typically include at leastone of two sensors: 1) a sensor for measuring the rotation of a cordreel spool within the housing and/or: 2) a sensor for measuring at leastone of the voltage, the resistance or the amperage flow within the cord.The smart cord reel system will typically include at least one memoryfor receiving an input from each of the sensor(s), where the memorystores records from the inputs provided by the sensors, and sensor isaccessible by a processor (whether local to the cord reel system,proximate in the form of a laptop or other handheld interrogationdevice, or remote as in a server connection), wherein the processorcan—among other tasks—compare the records in memory againstpredetermined limits to provide a status signal therefrom to indicatewhether the replacement or repair of the cord reel assembly or somecomponent thereof is required.

The immediate application of the present invention will be seen in largescale cord reel placements (e.g., retractable data and low voltage powercord reel connections for controller and/or electronics on aircraft),though those of skill will see that the present invention could beapplied to electrical and non-electrical cord reels and/or non-vehicleusage (e.g., retail security usage, consumer and commercial electronicsusage) where information about the usage and/or wear of the cord reelmay be advantageous.

Thus can be seen that one object of the present invention is to providea mechanism for predicting the need to replace a cable or othercomponent in a cord reel assembly.

A further object of the present invention is to provide a mechanism forpredicting the need to replace the cord reel assembly as a whole.

Still another object of the present invention is to provide a cord orcord reel assembly that records usage events for analyzing the ways inwhich a cord or cord reel assembly is used.

Yet another object of the present invention is to provide a cord reelassembly that provides status information about the assembly toauthorized personnel.

Still another object of the present invention is to provide a cord reelassembly which reduces or eliminates down time of a given cord or cordreel assembly, as well as providing usage information that can beemployed to improve the future design of the cord reel assembly so as tobetter perform in a given environment.

A further object of the present invention is to provide a cord reelassembly having a stationary cord end and a retractable cord end, theassembly having a more compact profile.

Still another object of the present invention is to provide aretractable cord reel assembly having a stationary cord end and aretractable cord end, the cord reel assembly including a reliableelectrical contact for providing power and or data to a personal controlunit.

Yet a further object of the present invention is to provide a reliablemechanism for removal of a cord reel unit by service personnel withoutcompromising the normal operation of the system.

It should be noted that not every embodiment of the claimed inventionwill accomplish each of the objects of the invention set forth above. Inaddition, further objects of the invention will become apparent based onthe summary of the invention, the detailed description of preferredembodiments, and as illustrated in the accompanying drawings. Suchobjects, features, and advantages of the present invention will becomemore apparent in light of the following detailed description variousembodiments thereof, and as illustrated in the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a first example embodiment of cord reel assembly with arotational sensor for a cord reel spool in accord with a preferredembodiment of the present invention.

FIG. 2 shows alternative schematics for a smart cord reel assembly usinglocal and remote processing capabilities in accord with alternativeembodiments of the present invention.

FIG. 3 shows an example embodiment of cord reel assembly with aremovable cord segment and a maintenance release mechanism in accordwith a preferred embodiment of the present invention.

FIG. 4 shows an exploded view of an alternative retractable cablemechanism for use with an alternative embodiment of the presentinvention.

FIG. 5 shows an alternative embodiment of the cord reel assembly usingthe retractable cable mechanism of FIG. 4.

FIG. 6 shows yet another alternative cord reel for use with the smartcord reel system of the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

Set forth below is a description of what is currently believed to be thepreferred embodiment or best examples of the invention claimed. Futureand present alternatives and modifications to this preferred embodimentare contemplated. Any alternatives or modifications which makeinsubstantial changes in function, in purpose, in structure or in resultare intended to be covered by the claims in this patent.

FIG. 1 shows an example smart cord reel system 10 in accord with a firstpreferred embodiment of the present invention. Specifically, theassembly includes a cord reel assembly that is preferably comprised of ahousing 20 that has a spool 22 contained inside. The spool 22 rotatesrelative to the housing 20 so as to retract or extend a cord 23therefrom. The cord 23 is connected at the end opposite of the spool 22to a personal control unit 30 (also known as a passenger control unit),which could be any of a smart phone, a laptop, a dedicated videoentertainment device (which can be stored on a cradle 28) or even aremote control or the like. The cord 23 will typically supply dataand/or power to the personal control unit 30, though another alternative(as shown in FIG. 2) would provide for a wireless connection between thepersonal control unit and the spool, such that the sole purpose of thecord 23 in such an alternative embodiment would be for security andtethering.

Also contained with the housing 20 is a sensor 24 for measuring eachcomplete rotation of the spool 22 within the housing 20. In thispreferred embodiment, the sensor 24 is a Hall effect sensor that workswith one or more magnets on the spool 22 to count each compete rotationof the spool, though persons of skill in the art will understand thatother alternative structures may be used for measuring spool rotation,such as an optical sensor in combination with a color coated cord. Inaddition (or as an alternative to the rotational sensor 24), the housingmay further include a second sensor 25 for measuring the voltage and/orthe resistance and/or the amperage of the cord.

Each of these sensors 24, 25 are electrically connected to a memory 26.As shown in FIG. 2, the memory 26 can be located within the housing 20of a given unit, or it can be transmitted (via Bluetooth or similarcommunications protocol) to a nearby maintenance tablet 40 or similarsecure device which can be accessed by authorized personnel (e.g.,maintenance personnel or flight crew). In this embodiment, themaintenance tablet 40 could receive and record separate usage events foreach of a large number of personal control units 30 (e.g., each seat onan airplane, wherein each seat has its own personal control unit).Alternatively, the system 10 could link to a remote server 50 whichrecords and stores the stores the usage events in a memory thereon.

Regardless of the location of the memory 26, the usage records storedthereon in the present disclosure are accessible by at least oneprocessor 32, which may be located (for instance) on the maintenancetable 40 or the remote server. Depending upon the desired configuration,the output of the processor can be displayed on the maintenance tablet40 or a remote web based terminal 52 or the like. In one embodiment, theprocessor can compare the input of the sensors (e.g., the usage record)against preselected limits to determine whether the cord reel is workingwithin normal operational or life expectancy parameters.

For instance, the sensor 24 may have recorded 5996 rotations in a givenpersonal control unit (e.g., seat 7C of an aircraft, as reflected inFIG. 2). The manufacturer of the cord reel assembly may have (forinstance) mandated that the cord or cord reel be replaced at 8000rotations. Furthermore, the manufacturer may decide that it is advisableto warn the operator that replacement will be required soon in the eventthat the usage approaches that limit. For instance, using the example ofFIG. 2, the processor 30 may flash a warning or “yellow” signal afterthe personal control unit 30 in question has passed 6000 rotations,while flashing a “red” or immediate replacement signal once thepreselected limit of 8000 rotations has been exceeded.

Of course, those seeing the disclosure of the present disclosure willunderstand that its advantages are not limited to monitoring of normalmaintenance and replacement events. For instance, the second sensor 25may also record a decrease in resistance values or a spike in voltage oramperage indicative of a fault or other abnormal events. The system 10can provide for recording of such events in memory 26 such that theprocessor 30 can compare such event records against preset operatingvalues stored in a memory 26 to determine if another status signalshould be generated on the display of the maintenance tablet 40 or theweb terminal 52 to instruct authorized personnel to replace the cord 23or the cord reel assembly 16.

Furthermore, the events recorded in memory may not be directly relatedto wear and tear or malfunction, but may simply relate to operatingmetrics to facilitate the analysis of operation of the system 10 formarketing analytics or ongoing improvements in maintenance and/ordesign. Examples of such operating metrics can include, by way ofexample, first date in use (e.g., to track the expect amount of time inthe field prior to replacements), serial number, maintenance records(including a recommended date for next maintenance), install type,installation location and parameters, frequency of use, and extent ofuse. In such time sensitive measurements, those of skill in the artwould understand that a clock 27 would be required in addition to thememory 26 to provide the appropriate time stamp or similar tracking. Theaddition of a clock 27 in combination with the usage records couldpermit (for instance) alteration of the recommended date for nextmaintenance based upon changes in the frequency of use.

The analysis by the processor 30 could also entail analysis of usagerecords which impact the ongoing redesign of the cord reel assembly. Forinstance, a number of cord reel assemblies 16 might provide informationfrom their respective sensors 24 indicating (for instance) that the vastmajority of cord extensions for a given unit involve far less than thefull length that the cord 23 may be extended, thus prompting thedesigners to provide alterations to the design of the cord reel assembly16 with a shorter cord 23, thereby providing cost savings to the system10.

Another alternative of usage analytics would be particularly applicableto a security application of the cord reel assembly. For instance, aseries of cord reel assemblies 16 might provide information from sensors24 and/or 25 indicating that various attached electronic devices hadbeen picked up at a given times and/or powered for a given durations.The records related to such sensor information could be used byprocessor 30 to create analytic records to indicate (for instance) thetrend of usage of the various attached electronic devices, and thereforeinfer or otherwise provide data showing the comparative popularity ofthe respective attached electronic devices.

FIG. 3 shows an example cord reel system 110 in accord with a secondpreferred embodiment of the present invention for use with the smartcord reel system of the present invention (e.g., a mechanism forreplacing a cord reel unit in an instance where the smart cord reel hasa yellow or red signal has been incurred). The basic components of thisembodiment of the system include a holder 120, a user interface module130, and a cord reel unit 140.

The cord reel unit 140 can be of a variety of models such as the typefound in U.S. Pat. No. 5,094,396 to Burke, the subject matter of whichis hereby incorporated by reference, or U.S. Patent Application No.2007/0262185 to Burke, the subject matter of which is also herebyincorporated by reference, or U.S. Pat. No. 8,075,335 to Burke et al.,which is likewise incorporated herein by reference. The cord 142extending from the cord reel unit 140 is typically an electric cord reelwhich can supply power and/or data to the user interface module 130,though the cord 142 of the present invention could be simply limited toa mechanical attachment or tether to the user interface module 130,e.g., in the event of a wireless communication with any such userinterface module 130.

The user interface module 130 (also known as a passenger control unit)could be any of a smart phone, a laptop, a dedicated video entertainmentdevice or even a remote control or the like.

The holder 120 can be connected, for instance, to an interior surface ofan aircraft or vehicle. In this embodiment, the holder 120 is a cradlefor a phone or passenger control unit, though people of skill willunderstand that the holder could incorporate other types of surfaces,too. In this embodiment, holder 120 includes a maintenance accessmechanism 122 which in this embodiment is a button, which couldoptionally include a friction fit cover (not shown) to hide its presencefrom a user/passenger. Alternatively, the button 122 could be hidden ina less visible portion of the holder so as not to be easily actuated bya passenger. Likewise, the button 122 could take alternative forms, suchas a tool actuated aperture (a so called “toothpick” opening) so as tobe inaccessible by a user, or it could involve a wireless connection.Regardless of the alternative structure used, the button 122 is designedto open a solenoid (not shown) or similar lock such as a Nitinol or“muscle metal” latch with prevents the cord 142 from extending fullyoutside of the opening in the holder 120. By so unlocking, the portionof the cord 142 that includes the connector 150 is exposed. In thispreferred embodiment, connector 150 is a barrel type connector, such asbarrel type connectors sold by Switchcraft and Carlisle Interconnect,though people of skill in the art having the present teaching will beable to use other alternative connectors based upon the needs of theapplication. Thus exposed, the authorized personnel (e.g., the servicetechnician or flight crew member) who actuated the maintenance actuationmechanism can easily decouple the connector 150 to swap the cord 142with a replacement cord.

As shown in FIGS. 4 and 5, the smart cord reel system of the presentinvention can alternatively be used with a retractable cable or cordmechanism in lieu of a cord reel mechanism. In this alternativeembodiment, the assembly 210 comprises a cradle 220, a handset 230 (orany other personal control unit), and a cord management unit 240, whichextends and retracts a retractable cable for use. In this embodiment, inlieu of a reel, the cord management unit 240 comprises a housing 244 anda cover 252 for containing the retractable cable 242 when retracted. Thecord management unit 240 enables retraction and extension of the cablethrough a roller mechanism 248 which works cooperatively with a seriesof springs so as to slide or collapse the rollers of the rollermechanism together to allow for more slack to support extension of theretractable cable 242 as needed, while maintaining the other end of thecable 246 stationary. In such instances, the sensors 24, 25 fordetermining usage of the retractable cord as discussed in FIGS. 1 and 2may be connect to the roller mechanism 248 to the processor and memory(not shown) to determine the number of extension cycles for theretractable cable and compare the number of extensions againstpredetermined limits, if desired.

Further, it can be seen that other, alternative embodiments of the cordreel unit may be used in the present invention. For instance, as shownin FIG. 6, the present invention can include a cord reel unit 340comprising a housing 344 and a cover 360 for retaining and extending aretractable cable 342 around a spool 350. The cord reel unit mayoptionally include a ratchet mechanism 348 for limiting the retractablemovement of the retractable cable 342. The cord reel unit 340 enablestransmission of power, electrical and/or optical signals from theretractable cable 342 to the stationary cable 346 via a slip ringmechanism (which can, alternatively, comprise a ball seal mechanism).The Slip ring mechanism in this embodiment comprises an inner slip ring358 which rotatably and substantially continuously contacts the outerslip ring 354 for transmitting between the stationary cable 346 and theretractable cable 342, with the slip ring mechanisms being held in placeby the spring spacer 356 and the spring and retainer 352.

The above description is not intended to limit the meaning of the wordsused in the following claims that define the invention. Rather, it iscontemplated that future modifications in structure, function or resultwill exist that are not substantial changes and that all suchinsubstantial changes in what is claimed are intended to be covered bythe claims. For instance, the specific spool rotation sensing mechanismused in the examples of the preferred embodiments of present inventionis for illustrative purposes with reference to the example drawingsonly. Similarly, while the preferred embodiments of the presentinvention are focused upon use within a cord reel assembly, those ofskill in the art will understand that the invention has equalapplicability to cable sensors related to resistance, voltage andamperage characteristics that are independent of the operation of aspool (or even without need for a cord assembly that uses a spool). Inaddition, persons of skill will appreciate that the present inventionwill have particular applicability to security application including,for instance, point of sale displays that require a secure connection toelectronics devices being offered for sale. Likewise, it will beappreciated by those skilled in the art that various changes, additions,omissions, and modifications can be made to the illustrated embodimentswithout departing from the spirit of the present invention. All suchmodifications and changes are intended to be covered by the followingclaims.

What is claimed is:
 1. A smart cord reel system including a maintenanceprediction mechanism for anticipating and predicting the need forreplacement, the system comprising: a) a cord reel assembly, including ahousing having a spool and a retractable cord segment that can beretracted and extended from the housing, a first sensor for measuringeach complete rotation of the spool within the housing and a secondsensor for measuring the voltage of the cord; b) at least one memorylocated within the cord reel assembly for receiving an input from thefirst sensor correlating to each complete rotation of the spool withinthe housing and keeping count of the sum of such rotations and receivingan input from the second sensor representative of at least one of theelectrical resistance of the cord, the voltage level of the cord or thecurrent received through the cord; and c) a processor electricallyconnected to the at least one memory for comparing the sum of rotationsfor the electric cord reel assembly against predetermined limits andproviding a status signal therefrom to indicate whether the replacementof the electric cord reel assembly is required, and the processorfurther connected to the at least one memory for comparing the inputfrom the second sensor representative of the electrical resistance ofthe cord against predetermined limits stored in memory and generating astatus signal therefrom to indicate whether replacement of at least aportion of the cord reel assembly is required.
 2. A smart cord reelsystem including a maintenance prediction mechanism for anticipating andpredicting the need for replacement, the system comprising: a) a cordreel assembly, including a housing having a spool and a cord that can beretracted and extended from the cord, and at least a first sensor; b) atleast one memory and a clock connected thereto located within the cordreel assembly for receiving an input from the first sensor correlatingto each complete rotation of the spool within the housing and keepingcount of the sum of such rotations and receiving an input from thesecond sensor representative of the electrical resistance of the cord;and c) a processor electrically connected to the at least one memory forreceiving data representative of rotations for the cord reel assembly,and generating usage analytic records therefrom.
 3. A smart cord reelsystem including a mechanism for delivering usage analytic recordsrelated to electronic devices attached thereto, the system comprising:a) a cord reel assembly, including a housing having a spool and aretractable cord segment that can be retracted and extended from thecord, and sensor; b) at least one memory located within the cord reelassembly for receiving an input from the sensor correlating to at leastone of i) rotation of the spool within the housing; ii) the voltagewithin the cord; iii) the resistance within the cord; or iv) theamperage flow within the cord; and c) a processor electrically connectedto the at least one memory for receiving data representative of theinput from the sensor, and generating usage analytic records therefrom.